- First Name
- Mark
- Joined
- Apr 20, 2022
- Threads
- 9
- Messages
- 164
- Reaction score
- 129
- Location
- Los Angeles
- Vehicle(s)
- 2022 Bronco BlkDia. Sasquatch
- Your Bronco Model
- Black Diamond
- Thread starter
- #1
Hi Everyone,
I decided to start a new thread about making some Add-ons to the OEM Roof Rack. No one has really created anything besides some people posting about DIYing their own brackets. I'm surprised no other company has come up with more Mounting Options for it. Maybe since the OEM rack is limited in it's capacity no one wants to put in the time to make anything.
Being that I'm an Engineer, I'm the type of person that will make my own parts like so many other people, if I have time. That being said, I've been working on some Bracket/Mounting Plate designs for the OEM Roof Rack. These would be able to mount Aluminum Extrusion Cross Bars with T-Slots for more roof add on options.
See my two designs that I created. I've seen other roof rack manufacturers make similar mounting plates for other vehicles, but so far nothing for the Bronco OEM Roof Rack.
This is still a work in progress, but I'd like to get some feedback and suggestions for my designs. If you have any suggestions let me know and I can see about adding to the designs. Also, I want to see if it's worth pursuing to have these made. I have a place that can laser cut the plates & bend them using Aluminum or Steel. I was thinking Aluminum due to it being lightweight. The plate thickness I was thinking of using .187" thick unless .25" thick would be better for these. They also can Powder-coat the plates.
Tnutz is the place I heard about that can provide the Cross Bar Extrusions, Cut to length & with mounting holes pre-drilled for a good price.
Option A: essentially this has the Bracket follow the OEM Rail profile. I created a plate on the bottom to fully secure it to the entire Rail. I added slot holes for all mounting points to make it more versatile. On the outside extension part of the plate it has slots so anyone can add accessories like an awning or other items. You can add an Aluminum T-slot Extrusion bar along the outside plate face thus connecting the two brackets. *See the last CAD image I made showing this added side mount Tslot Extrusion. This would make it more universal for adding more stuff. This option has a lot of bending involved so it will be higher in cost.
Option A -Estimate: at least $250 or more per cross bar set = (this would include four plates -Left/right -top & bottom plates, +powder coated, plus one black cross rail extrusion from Tnutz with the pre-drilled holes/tapped end holes etc. and all hardware I still need to source). *With Higher Qty it could be $200 per set or less. *If you only wanted one set of plates or sold in pairs, it would be around $150 (Left/Right Top Bottom-set), -or- One set Top/Bottom plate for $100 maybe.
Option B: this is the simple approach that is similar to "another roof rack manufacturer" I saw but they don't have the Bronco in their line up. These simple plates mount the to the existing threaded holes on the OEM rails. You can mount the Cross Bar above the OEM rail or below the rail. I have two designs, one has both hole mounts.
Option B -Estimate: $150 per cross bar set = (again it would include two plates for mounting one cross bar with the pre-drilled holes/tapped end holes etc. plus hardware). *With Higher Qty it could be $100 per set or less. *If you only want the plates, I guess one set would be around $40 (pair).
Granted those prices are only estimates I based on what it would take to have the plates custom made. If I get a higher quantity the cost would be lower. I'm also working on other designs for other parts on the bronco.
I don't have anything laid out yet for the Cross bar in the back where it mounts to the Hardtop. The plastic covering is formed to match the oval OEM cross bars which don't have any T-Slots and they have thin walls too. I'm sure if you wanted to add one of the Rectangular Extrusions you would need to cut some of the plastic to fit it between the plastic covers. Something I'm still thinking about.
Nothing is finalized and I still need to make some test pieces via 3D printing to try out first. I will also need to get the Aluminum Extrusion and see about testing it.
*Disclaimer: this wouldn't increase the weight capacity of the OEM rack. The main idea is to make the OEM rack more useful to us for adding other attachments with more mounting options. This wouldn't be for mounting heavy Rooftop tents.
Let me know what you think and which one would you be interested in if I have them made. I can see about selling them.
Thanks!
**Yesterday I tested out a cardboard template for the Option B mounting plate with the double position cross bar. The bottom position still clears the roof, but I'm not sure if you could remove the roof panels which would need to be tested.
I decided to start a new thread about making some Add-ons to the OEM Roof Rack. No one has really created anything besides some people posting about DIYing their own brackets. I'm surprised no other company has come up with more Mounting Options for it. Maybe since the OEM rack is limited in it's capacity no one wants to put in the time to make anything.
Being that I'm an Engineer, I'm the type of person that will make my own parts like so many other people, if I have time. That being said, I've been working on some Bracket/Mounting Plate designs for the OEM Roof Rack. These would be able to mount Aluminum Extrusion Cross Bars with T-Slots for more roof add on options.
See my two designs that I created. I've seen other roof rack manufacturers make similar mounting plates for other vehicles, but so far nothing for the Bronco OEM Roof Rack.
This is still a work in progress, but I'd like to get some feedback and suggestions for my designs. If you have any suggestions let me know and I can see about adding to the designs. Also, I want to see if it's worth pursuing to have these made. I have a place that can laser cut the plates & bend them using Aluminum or Steel. I was thinking Aluminum due to it being lightweight. The plate thickness I was thinking of using .187" thick unless .25" thick would be better for these. They also can Powder-coat the plates.
Tnutz is the place I heard about that can provide the Cross Bar Extrusions, Cut to length & with mounting holes pre-drilled for a good price.
Option A: essentially this has the Bracket follow the OEM Rail profile. I created a plate on the bottom to fully secure it to the entire Rail. I added slot holes for all mounting points to make it more versatile. On the outside extension part of the plate it has slots so anyone can add accessories like an awning or other items. You can add an Aluminum T-slot Extrusion bar along the outside plate face thus connecting the two brackets. *See the last CAD image I made showing this added side mount Tslot Extrusion. This would make it more universal for adding more stuff. This option has a lot of bending involved so it will be higher in cost.
Option A -Estimate: at least $250 or more per cross bar set = (this would include four plates -Left/right -top & bottom plates, +powder coated, plus one black cross rail extrusion from Tnutz with the pre-drilled holes/tapped end holes etc. and all hardware I still need to source). *With Higher Qty it could be $200 per set or less. *If you only wanted one set of plates or sold in pairs, it would be around $150 (Left/Right Top Bottom-set), -or- One set Top/Bottom plate for $100 maybe.
Option B: this is the simple approach that is similar to "another roof rack manufacturer" I saw but they don't have the Bronco in their line up. These simple plates mount the to the existing threaded holes on the OEM rails. You can mount the Cross Bar above the OEM rail or below the rail. I have two designs, one has both hole mounts.
Option B -Estimate: $150 per cross bar set = (again it would include two plates for mounting one cross bar with the pre-drilled holes/tapped end holes etc. plus hardware). *With Higher Qty it could be $100 per set or less. *If you only want the plates, I guess one set would be around $40 (pair).
Granted those prices are only estimates I based on what it would take to have the plates custom made. If I get a higher quantity the cost would be lower. I'm also working on other designs for other parts on the bronco.
I don't have anything laid out yet for the Cross bar in the back where it mounts to the Hardtop. The plastic covering is formed to match the oval OEM cross bars which don't have any T-Slots and they have thin walls too. I'm sure if you wanted to add one of the Rectangular Extrusions you would need to cut some of the plastic to fit it between the plastic covers. Something I'm still thinking about.
Nothing is finalized and I still need to make some test pieces via 3D printing to try out first. I will also need to get the Aluminum Extrusion and see about testing it.
*Disclaimer: this wouldn't increase the weight capacity of the OEM rack. The main idea is to make the OEM rack more useful to us for adding other attachments with more mounting options. This wouldn't be for mounting heavy Rooftop tents.
Let me know what you think and which one would you be interested in if I have them made. I can see about selling them.
Thanks!
**Yesterday I tested out a cardboard template for the Option B mounting plate with the double position cross bar. The bottom position still clears the roof, but I'm not sure if you could remove the roof panels which would need to be tested.
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